Beverage pod

ABSTRACT

A beverage pod is provided. The beverage pod includes an outer shell, a filter, and a shelf. The outer shell has a bottom layer, a lid opposite the bottom layer, and side walls between the bottom layer and the lid. The bottom layer is operable to be breached by a brewing pin from a beverage brewing machine. The filter forms a chamber operable to contain a beverage material. The beverage material is operable to mix with a liquid to form a beverage. The shelf supports a shape of at least a portion of the filter. The shelf forms a receiving portion operable to receive the brewing pin. The receiving portion has substantially a toroidal shape.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority benefit to U.S. Provisional Patent Application No. 63/029,078, filed in the U.S. Patent and Trademark Office on May 22, 2020, which is incorporated herein by reference in its entirety for all purposes.

FIELD

The present disclosure relates to a beverage pod such as, for example, a compostable beverage pod for single-serve use. The present disclosure further relates to the beverage cartridges or pods for use in single serving beverage brewing machines, for example beverage pods that are biodegradable.

BACKGROUND

The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.

Single-serve beverage pods have become a dominant method for serving beverages, especially hot beverages, in a variety of settings such as homes, offices, waiting rooms, hotel rooms and lobbies, and other places where people consume beverages. The rapid growth of single-serve beverage pods is driven by consumer preference for convenient, quickly prepared beverages in single-portion quantities, in a variety of flavors, beverage types (coffee, espresso, decaffeinated coffee, tea, decaffeinated tea, cider, hot cocoa/chocolate, bone broth, and even alcoholic beverages, such as, for example, Irish Coffee, Hot Toddy, Hot Buttered Rum, etc.). Even within a beverage type, such as coffee, there may be a plurality of roasts and associated roasters, flavor profiles, flavor additives, caffeine strengths, location or locations of origin, etc.

The convenience and variety of single serving beverage pods allows and encourages consumers to prepare and consume a plurality of beverages throughout the day. This pattern of consumption causes the rapid accumulation of used beverage pods wherever they are consumed. Due to the nature of single-serving beverage pods, a considerable amount of packaging waste is produced per beverage consumed compared to preparing beverages by traditional means, such as, for example, preparing a plurality of servings at once using bulk ingredients. Packaging waste, according to the United States Environmental Protection Agency (EPA), defines outer shells and packaging as products that are assumed to be discarded the same year the products they contain are purchased. The EPA further estimates that the majority of the solid waste are packaging products. Packaging waste contributes significantly to global pollution, the introduction of contaminants into the natural environment that cause adverse change, which poses a health risk many forms of life, including humans, other animals, plants, fungi, etc.

BRIEF DESCRIPTIONS OF THE DRAWINGS

FIG. 1A illustrates an example beverage brewing system.

FIG. 1B illustrates an example of a conventional beverage pod.

FIG. 1C illustrates a schematic view of a portion of a beverage brewing machine.

FIG. 2 illustrates an example beverage pod with a shelf

FIG. 3A illustrates another example of a beverage pod with a shelf.

FIG. 3B illustrates a top view of cross-section 3B-3B of FIG. 3A.

FIG. 4A illustrates a top view of a shelf.

FIG. 4B illustrates a cross-sectional view of a beverage pod with the shelf of FIG. 4A disposed within.

FIG. 4C illustrates a bottom, perspective view of the shelf of FIG. 4A.

FIG. 4D illustrates a bottom view of the shelf of FIG. 4A.

FIG. 4E illustrates a cross-sectional view of the shelf of FIG. 4D taken along 4E-4E.

FIG. 4F illustrates an enlarged portion of FIG. 4E.

FIG. 4G illustrates a cross-sectional view of the shelf of FIG. 4D taken along 4G-4G.

FIG. 4H illustrates an enlarged portion of FIG. 4G.

DETAILED DESCRIPTION

Disclosed herein is a single-serving beverage pod that increases and/or maximizes the amount of beverage material. The beverage pod includes additional volume compared to a conventional beverage pod. The beverage pod includes a shelf that can support the shape of the filter. The shelf forms a receiving portion operable to receive a brewing pin from a brewing beverage machine. The receiving portion can have substantially a toroidal shape, as the chamber (or additional chamber(s)) extend towards the bottom layer of the beverage pod while avoiding the brewing pin. Accordingly, the volume of beverage material(s) can be increased and/or optimized to provide a better beverage.

Single-serve beverage pods can include several components made of various materials. For example, the components of a single-serve beverage pod can include, at least, an outer shell, for example made from plastic such as polyethylene, a filter, for example made from plant fiber such as abaca fibers or other natural and synthetic fibers, and a outer shell lid, for example made from food-grade aluminum foil, which is also commonly printed upon to include product labelling. Some beverage pods do not contain a filter because the beverage material is readily soluble in hot water (such as, for example, hot cocoa). The outer shell can include an opening on the top of the outer shell, and a hollow cavity within which and across which a filter may be disposed. The outer shell may also include an opening at on the bottom outer shell. After the filter and beverage material are inserted into the outer shell, the lid is then typically sealed over the outer shell opening or openings. The sealed lid typically provides an airtight seal, preventing the exchange of gases between the environment and the interior of the outer shell, thus preventing oxidation and/or spoilage of the beverage material. In beverage pods that comprise a filter, the filter may separate the outer shell into two chambers: a first chamber occupying the space within the outer shell between the filter and the opening of the outer shell, the first chamber for holding dry beverage ingredients such as, but not limited to, coffee, tea, or cocoa, for a single beverage serving; and a receiving portion occupying the space within the outer shell between the filter and the bottom of the outer shell, the receiving portion being on the opposite side of the filter to the first chamber.

The purpose of the receiving portion is typically to provide a space in which a fluid extractor of a beverage brewing device may be inserted into the bottom of the outer shell, entering the receiving portion and allowing the extraction of fluid from the pod without the fluid extractor entering the first chamber, such that fluid must flow through the beverage material and the filter before exiting the pod via the fluid extractor. However, the presence of the second chamber may significantly reduce the space within the outer shell that can be occupied by beverage medium. This may be problematic as the total amount of beverage material disposed within the outer shell may significantly contribute to the final concentration of the beverage, typically measured in Total Dissolved Solids (TDS). It may be advantageous to minimize the volume of the second chamber in order to maximize the volume on the third chamber, thereby maximizing the total volume available for beverage material. However, the fluid extractor is typically comprised of a sharp, hollow needle-like piercing element designed to easily pierce through the bottom of the outer shell, such that if the second chamber is reduced in size, the fluid extractor may penetrate or damage the filter, allowing the beverage material to exit the first chamber, and ultimately exit the pod via the fluid extractor. Thus, in the event the fluid extractor penetrates or damages the filter, the beverage material may be transported into the final beverage, which may be undesirable to consumers (such as, for example, the presences of coffee grounds in a prepared cup of coffee) and may potentially damage the beverage brewing machine (for example, by way of clogging the fluid extractor with beverage material).

The lid is disposed over the opening of the outer shell (which may be, for example, over the top of the outer shell, and/or bottom of the outer shell), and keeps the dry beverage ingredients within the outer shell, as well as providing an airtight seal to prevent the oxidation and other types of degradation of the outer shell's contents. In practice, a single-serving beverage pod is placed into a compartment of a brewing machine. The machine is activated such that a fluid injector penetrates the cover of the pod and a fluid extractor penetrates the base of the pod (which may also be a cover). The fluid injector injects a brewing medium (e.g. hot water) into the first chamber for extracting beverage components from the ingredients. The brewing medium containing the extracted beverage components percolates through the filter and into the second chamber. The brewing medium containing the extracted or dissolved beverage is then extracted by the fluid extractor and finally dispensed as a drinkable beverage.

Conventionally, the outer shell of a beverage pod for single-serve use is typically made from petroleum-based plastic materials which are neither biodegradable nor compostable. In some cases, the outer shell may be made of petroleum biodegradable materials, such as Polybutylene adipate terephthalate (PBAT). While these materials may eventually biodegrade, they are not desirable for use in home or industrial composting settings, as they may pollute the compost with petroleum residue, microplastics, and other chemicals that may not be desirable for compost. Composting is the mixing of various decaying organic substances, such as dead plant matter, which are allowed to decompose to the point that various waste products of the composting process provide nutrients to be used as soil conditioners/fertilizers. Composting can be aerobic, anerobic, and/or vermicomposting, depending on the environment in which the compost is prepared. Aerobic composting is the decomposition of organic matter by microbes that require oxygen to process the organic matter. The oxygen from the air diffuses into the moisture that permeates the organic matter, allowing it to be taken up by the microbes. Anerobic composting is the decomposition of organic matter by microbes that do not require oxygen to process the organic matter. To be anerobic, the system must be sealed from the air, such as with a plastic barrier. Anerobic compositing produces an acidic environment to digest the organic material. Vermicomposting is the decomposition of organic matter by worms and other animals (such as soldier flies). A portion of the organic matter is converted to vermicast, or castings from the worms or other animals. The breakdown of the organic matter into vermicast yields an effective soil conditioner and/or fertilizer.

The lid of a beverage pod can be made of a polypropylene and a metal foil (e.g., aluminum) or a metal foil laminate which is affixed to the top of the outer shell with thermal welding or some other means (e.g. adhesives). Generally, neither the metal foil of the cover nor the glue affixing the cover over the opening of the outer shell is biodegradable, compostable, or made from readily renewable resources. As a result, non-biodegradable and non-compostable beverage pods typically end up in landfills, thereby at least contributing to environmental concerns associated with disposal of trash. This may be especially problematic due to the fact that traditional means of brewing beverages, e.g., using solely beverage material and filter material, or a filtration device (such as a French press, or a wire mesh filter) may yield a completely compostable waste product (e.g., spent coffee grounds and potentially a used paper filter).

Attempts have been made to recycle plastic beverage pods in some cases. Recycling has many issues which effect the efficacy and practicality of these programs. The first is collection and transportation. Collection largely requires voluntary compliance by consumers. Some deposit programs encourage consumers to return recyclable materials, however this accounts for very few recyclable materials. Collection is further complicated by the need to further transport the materials to a facility which can process them. Many of these facilities are run by municipalities as recycling operations frequently lack economic viability without government subsidies. Recycling of plastics and other materials is further complicated by cross contamination and downcycling. Cross contamination is the presence of foreign materials not desired in the end product and can include materials such as other non-recyclable waste, or other recyclable wastes not compatible with the desired recycled material which can include other plastics. This requires sorting and cleaning of materials. This process may be partially automated; however, it also requires manual sorting and inspection which adds cost, reduces the amount of material that can be processed and inevitably results in a less pure product than when using virgin material. This frequently results in downcycling.

Downcycling is the term used to describe the reduction of quality in recycled materials compared to materials prior to being recycled. Impurities introduced during processing, from non-recyclable waste that could not be removed, or from other plastics and materials can make the resulting material unsuitable for use in their original applications. As such, the applications for recycled materials, especially plastics, are limited, as is the number of times that plastics can be recycled.

Beverage outer shells, such as instant beverage cups or pods, can be particularly difficult to recycle. Not only do they have non-recyclable material contained within them that would first need to be removed, they are frequently comprised of at least two different materials, such as a plastic cup and an aluminum foil lid. When the lid is made of plastic, it is often a different type than the cup, and would require separation prior to processing when being recycled. This increases the complexity of the recycling operation, requiring at least three separate streams for each type of refuse, each requiring their own preparation. Furthermore, the small size of these beverage pods creates a disproportionate amount of effort required to recycle a small amount of material. The separation of materials would ideally be performed by the consumer prior to recycling; however, this inconvenience will inevitably result in consumers recycling the beverage outer shells without proper preparations, or failing to recycle the outer shell at all, electing to discard the outer shell as trash. One of the major advantages of using beverage pods is consumer convenience, such that a beverage can be prepare by simply inserting a pod into a machine that performs all other brewing functions. It is therefore undesirable to instruct consumers to disassemble and sort various materials from the beverage pod, and due to the diminutive size of beverage pods, this may not be physically possible for consumers without fine motor skills necessary to disassemble such an item. The result is a required step of preprocessing the outer shells before they can be recycled to ensure the materials are separated and the recyclable material sufficiently cleaned.

Plastics are traditionally sourced from petroleum. They are processed with chemicals to create polymers which can then be formed into shapes. Such polymers that are heated to be formed and then hold their shape when cooled are called thermoplastics. Many of the chemicals used to produce these polymers are inherently toxic and can leech into the contents. This is why few types of plastics are approved for use with foods. Some materials may be safe storing some types of food products, such as dry goods, however when a solvent is introduced, the chemicals in the plastic can go into solution. In the past, some plastics that were previously approved for use with foods have been found to leech chemicals, such as BPA (Bisphenol A). Other chemicals that can be found in plastics include thalates, antiminitroxide, brominated flame retardants and poly-fluorinated chemicals. Depending on the chemical and the manner in which the plastic is being used, it can cause problems including irritation in the eye, vision failure, breathing difficulties, respiratory problems, liver dysfunction, cancers, skin diseases, lung problems, headache, dizziness, birth defects, as well as reproductive, cardiovascular, genotoxic and gastrointestinal issues.

There has been a push from some governments to mandate composting and increase the amount of recycled material to reduce the amount of waste being incinerated or buried in landfills. Some laws such in the European Union, set specific targets, such as 65% of waste recycled by 2035. In the United States, there is no national law, but roughly half of states have some form of recycling law and municipalities may further add to these laws resulting in a varying patchwork of regulations and mandates. Some laws are very limited, requiring that some bottles and cans be recycled. Many of these states also add deposits to bottles, adding monetary value and incentive to returning them for recycling. Others require only specific recyclable materials be recycled, while others may be permitted to be discarded in the trash. Some states go further, mandating that compostable waste be disposed of properly, either in a home composter, or via an industrialized composting operation.

A further complication to composting plastics is that not all plastics break down the same. Some plastics, whether petroleum based or bioplastics, which originate from biomass, are biodegradable. Only a small subset of these are also compostable. The distinction lies in how quickly the plastic breaks down, and whether the process of degradation releases harmful chemicals into the environment. Compostable plastics typically degrade within 12 weeks, wherein biodegradable plastics will typically break down within 6 months. Ideally, compostable plastics would break down at the same rate as common food scraps, about 90 days.

Another class of plastics are OXO-degradable plastics. These are different than biodegradable plastics in that they are traditional plastics with additional chemicals which accelerate the oxidation and fragmentation of the materials under UV light and/or heat. This allows the plastics to break down more quickly, however the result is pollution from microplastics, as the plastic molecules themselves do not degrade any faster than their traditional plastic counterparts. There have been efforts in some jurisdictions to ban these plastics.

Single serving beverage pods that contain a beverage filter require measures to be taken to prevent the piercing element in the beverage brewing machine's outlet from its brewing chamber from damaging that filter, as it would yield beverage material, such as coffee grounds (or other beverage material, such as tea, or soluble material such as cocoa), entering the user's beverage. A common step taken in the industry to prevent the filter from being damaged, is to leave an empty space below the beverage filter that is large enough so as to prevent the piercing element from damaging the filter. This reduces the available space for beverage material, thus restricting the potential concentration of the resulting beverage, which could be measure, for example, as total dissolved solids (TDS), which reduces the possible strength of flavor and actives (such as caffeine) in the beverage brewed from the pod.

One system for maximizing the TDS in a beverage pod, while protecting the beverage filter from the piercing element, is to install a filter guard. This adds to the complexity of the manufacturing process by requiring an additional part that must be created and positioned properly during the assembly of the pod. Furthermore, the filter guard may be undesirable for other reasons, such as, for example, potential for beverage failure, such as damming or clogging the piercing element. In some cases, the filter guard may be made of thicker or denser material than the rest of the beverage pod, which would reduce or eliminate the potential of composting the pod in a timely fashion (e.g. 90 days).

It is therefore desirable to protect the beverage filter from being damaged by the piercing element in a beverage brewing machine, while maximizing the TDS in the beverage pod and simplifying the assembly process. There exists a need to provide a beverage pod which is capable of avoiding the piercing element while maximizing the available space for beverage material.

FIG. 1A illustrates a beverage brewing system 10 operable to brew a beverage. The beverage brewing system 10 includes a beverage brewing machine 3 and a beverage pod 20. The beverage brewing machine 3 is operable to receive the beverage pod 20 and may be used to form any suitable beverage, such as tea, coffee, or other infusion-type beverages. Beverages may be formed from a liquid and/or dry materials, for example to make soups, juices or other beverages made from dried materials, other materials. The beverage brewing machine 3 can create a beverage that is deposited into a user's cup 7. In at least one example, the user can position the cup 7 onto a platform 18. In some examples, the user may position the cup 7 on a table top. The beverage pod 20 can be inserted into a pod holder 9 which has a brewing chamber 11 operable to receive the beverage pod 20. In at least one example, the beverage pod 20 may be manually or automatically placed in the pod holder 9. A cover 8 can at least partially cover the brewing chamber 11 to at least partially enclose the beverage pod 20 in the pod holder 9 in which the beverage pod 20 is used to make a beverage.

FIG. 1B illustrates a beverage pod 20, for example an example of a conventional beverage pod 102. Beverage pods 102, or beverage cartridges, are outer shells, pods, capsules, etc., for use in the beverage brewing machine 3, such as a coffee maker. The beverage pod 20 may include one or more of, a beverage medium 116 that is either soluble or insoluble, one or more filters 114, and a first portion 115 in which liquid is passed into and a second portion 112 through which liquid passes out of the beverage pod 20. In some examples, the beverage pods 20 can be portioned beverage packages that can contain a water-soluble material, to make a drink such a hot chocolate, chai tea, etc. These portioned packages can be pouches as well as pods for beverage brewing machines 3.

The beverage pod 102 can contain a number of components, including lid 104. The lid 104 is operable to close the beverage pod 102 to contain the beverage medium 116 in the first portion 115. The lid 104 can be made of, for example, a foil that is sealed to the beverage pod 20 so as to contain the beverage material 116. A compostable lid 104 may be comprised of, for example a spun bond PLA web film (which may contain, for example, a proportion of PHA), a cellulose paper film, etc. The pod bond 106 is the connection between any two of the lid 104, outer shell 108, and/or pod interior 110. The pod bond 106 can be mechanical or chemical, and such as adhesives, heat sealing, ultrasonic welding, etc. The pod bond 106 can be in one place or separately depending upon the use case. The pod bond 106 can include a filter bond that binds the filter medium to a portion of the beverage pod 20, such as by ultrasonic welding, adhesives, thermal sealing, etc.

A pod exterior 108 is the outer shell of the beverage pod 20. The exterior 108 can be made of plastic (especially compostable plastic, such as PLA, PHA, or combinations thereof), cellulose, etc. The pod exterior 108 can have similar properties to other thermoplastic polymers such as polypropylene (PP), polyethylene (PE), or polystyrene (PS). This allows it to serve as a biodegradable alternative for coffee pods. In some examples, the pod exterior 108 can also be made from polyhydroxyalkanoates (PHAs), which are a biodegradable polyester produced through bacterial fermentation of sugar or lipids. The pod exterior 108 can be used as alternatives to other synthetic plastics. The mechanical properties of PHAs can be modified for a given use case by blending it with other biodegradable polymers, such as PLAs. They can also be made from poly(L-lactide) (PLLA), which is a polymer that is also biodegradable and compostable. The material may be used to form various aspects of the beverage pod 20. PLLA is also readily renewable, typically made from fermented plant starch such as from corn, cassava, sugarcane, or sugar beet pulp. Cellulose fibers are fibrous materials made from plant materials such cotton, flax, wood pulp, etc. Cellulose fibers can provide a biodegradable filter material that could be used in coffee pods. Other materials that are biodegradable plastic alternatives include petroleum-based plastics such as, Polyglycolic acid (PGA), Polybutylene succinate (PBS), Polycaprolactone (PCL), Polyvinyl alcohol (PVOH), and/or Polybutylene adipate terephthalate (PBAT).

In some examples, beverage pods 20 can also contain a pod interior 110 that is separate from a filter 114, in beverages that have an insoluble beverage material such as coffee. The pod interior 110 can be used for a number of purposes, including, providing material properties such as structural integrity (e.g., provide addition strength to resist the pressure of liquid injection in the process of brewing a beverage, which may crack or otherwise compromise the beverage pod 20), and/or altering the biodegradability or rate of the beverage pod 20. A registration element 112, or faceplate, is a solid structure integrated into a beverage pod 20 that prevents the brewing pin 126 (shown in FIG. 1C) from creating a path for the insoluble beverage material from inside the filter 114 to the outlet. In some examples, the pod interior 114 may include integrated features to act as a registration element 112, removing the requirement for a discrete component.

The filter 114 can be a medium, such as spun bond PLA web, paper (cellulose), cloth or metal, that is used to prevent an insoluble beverage material 116 from leaving the beverage pod 20 and entering the beverage brewing machine 3 or the beverage. Filters 114 can be symmetrical (e.g., fluted), or asymmetrical (e.g. pleated).

Beverage material 116 is the material used to produce a brewed beverage, such as coffee grounds, tea, or a mix beverage where the beverage material is soluble, such as hot chocolate. Beverage material 116 may include any flavorings, nutritional content (e.g., any oils, nutritional supplements, active ingredients such as pharmaceuticals, cannabinoids, etc.), alcohol, coloring, or any other composition which has an effect on the final beverage.

Referring to FIGS. 1A, 1B, and 1C, beverage brewing machines 3 for brewing portioned beverages from pre-packed beverage pods 20 exist for a variety of beverages made from a beverage material 116 that is either insoluble, such as coffee, or soluble, such as hot chocolate. A beverage brewing machine 3 can contain many other components, such as, for example, a heating element, a liquid reservoir or plumbing component, a liquid pump, an exterior chassis, a controller for the brewing process, a display or indicator lights and sounds, a user interface including buttons or a touchscreen, a tray to catch spillage, etc. For the purposes of description, the beverage brewing machine 3 contains all components necessary to accomplish the beverage brewing process, though specific reference to beverage brewing machine components may only be made to those components which come into direct contact with the beverage pod 20, such as the brewing chamber 11, a fluid injecting component 124, and a brewing pin 126. The beverage brewing machine 3 can contain a fluid source 120 that supplies the liquid, which may be water, to the brewing machine 3 for producing the desired beverage. A cover 8 can be opened to allow a new beverage pod 20 to be added to the beverage brewing machine 3. The beverage pod 20 can be received in the brewing chamber 11. In some examples, the cover 8 contacts the fluid source 120 to the fluid injecting component 124, but the fluid source 120 does not have to be provided in the cover 120. A fluid injecting component 124 can be operable to breach the lid 104 and be in fluid communication with the first portion 115. In some examples, the fluid injecting component 124 can include a piercing component to pierce the lid 104. The fluid injecting component 124 can provide a liquid, typically hot water, to mix with the beverage medium 116 to create the beverage. A brewing pin 126 can be operable to breach the bottom of the beverage pod 20 to allow the brewed beverage to leave the beverage pod 20 and/or the brewing chamber 11. In some examples, the brewing pin 126 can be operable to breach the beverage pod 20 through the second portion 112. The second portion 112 may be located opposite the first portion 115 in relation to the filter 114 such that the beverage can be extracted without the beverage material 116. In some examples, the brewing pin 126 may pierce or deform other components of the beverage pod 20 to breach the beverage pod 20.

As shown in FIG. 1B, the conventional beverage pod 102 has a large receiving portion 160 disposed underneath the filter 114. The receiving portion 160 is disposed between the filter 114 and the bottom of the beverage pod 102. Conventionally, the filter 114 has a substantially flat bottom which is substantially parallel with the bottom of the beverage pod 102. Conventional beverage pods 102 leave such a large receiving portion 160 in order to prevent the brewing pin 126 from penetrating the filter 114. The brewing pin 126 can be fluidly coupled to an outlet through which the beverage can be deposited into the cup 7.

FIG. 2 illustrates the beverage pod 200 that includes a chamber 215 that provides additional volume for the beverage material 216 by extending the chamber 215 into the receiving portion 260. The filter 214 forms the chamber 215 operable to contain the beverage material 216. In some examples, the brewing pin 126 is positioned to breach the bottom 205 of the beverage pod 200 off-center. As illustrated in FIG. 2, the additional volume is provided by extending the chamber 215 into the central portion of the receiving portion 260 to avoid the brewing pin 126, as the brewing pin 126 would not be received in that portion of the receiving portion 260. For example, the chamber 215 can be substantially frustoconical in shape with an additional smaller frustoconical shape extending into the receiving portion 260 towards the bottom 205 of the beverage pod 200. In some examples, the chamber 215 can be substantially frustoconical in shape to confirm with the outer shell 208, and the additional volume can be in a shape such as cylindrical, rectangular prism, pyramidal, or any other suitable shape to add volume for the beverage material 216 while avoiding contact with the brewing pin 126.

In at least one example, the beverage pod 200 can include on single chamber 215 operable to contain a beverage material 216. The beverage material 216 can be used to combine with the liquid, for example water, to create a beverage. In some examples, the beverage material 216 can include tea leaves, coffee grounds, or any other suitable beverage material 216 that can be steeped or dissolved when in contact with the liquid from the fluid injection component 124.

In some examples, the beverage pod 200 can include two chambers 219, 220. The first chamber 219 can contain a first beverage material 216. The second chamber 220 can be provided as the additional volume that extends into the receiving portion 260 as discussed above. In at least one example, the second chamber 220 can contain a second beverage material 222 that is different than the first beverage material 216 to provide complexity to the beverage created. In some examples, the second chamber 220 can contain the first beverage material 216 but is provided as a second chamber 220 for easier manufacturing. In at least one example, the first chamber 219 and the second chamber 220 can be separated by a separation filter 218 that permits passage of fluids but keeps the first beverage material 216 and the second beverage material 222 separate from one another.

In at least one example, as illustrated in FIG. 2, the beverage pod 200 can include a shelf 250 that prevents the brewing pin 126 from interacting with the beverage material 216, as the beverage material 216 may clog the brewing pin 126 or be disposed into the user's cup 7. The shelf 250 provides a receiving portion 260 near the bottom 205 of the beverage pod 200 that would typically be empty so as to avoid the filter 214 being damaged by the brewing pin 126. This newly available volume in the pod 200, for example, may be approximately 7cc of the 13cc that is typically lost to prevent the filter 214 from being damaged by the brewing pin 126, can be filled in a number of ways. The filter 214 can have a protrusion at its center that corresponds to the shape of the shelf 200. This protrusion can be formed into a filter in a number of different ways. The edge can be, for example, created through a mechanical process, such as pressing the filter 214 into the shape between a male anvil and a female mold or die. In some examples, an energetic process may also used, such as, for example, an ultrasonic welding process, but could also be done with other methods such as, injection molding, vacuum thermoforming, additive manufacturing such as 3D printing, extruded, or any other means of achieving a filter 214 with the given protrusion. In some examples, the newly available volume could be filled with a second filter pouch to form the second chamber 220 (e.g., beverage material completely encapsulated by filter material, creating a sort of tea bag device or filter puck of beverage material), creating a filter barrier, or some other means.

In at least one example, the shelf 250 can be disposed between the filter 214 and the bottom 205 of the beverage pod 200 to prevent the brewing pin 126 from breaching or damaging the filter 214. The shelf 250 can be built into the beverage pod 200 that may be, for example, approximately 800 microns thick and runs along the wall at a height that is as low as possible while still protecting filter 214 from the brewing pin 126. FIG. 2 shows a 2 dimensional representation of the shelf 250; however, it is understood that, in some examples, the shelf 250 may be disposed around the entire circumference of the beverage pod 200. In other examples, the shelf 250 may serve on to support a shape of at least a portion of the filter 214 as water is injected into the beverage pod 200. In such examples, the shelf 250 may never contact the brewing pin 126. In some examples, the shelf 250 may not be a contiguous flat surface, but may be instead an array of protruding spokes placed around the circumference of the interior of the beverage pod 200 to serve the function of filter support and maintain the shape of the filter 214.

In some examples, the shelf 250 can be disposed inside the chamber 215 between the filter 214 and the lid 204. In such an example, the shelf 250 can function as a registration element to prevent the brewing pin 126 from interacting with the beverage material 216 even though the brewing pin 126 breached the filter 214. In at least one example, the shelf 250 can be disposed adjacent to the bottom of the filter 214. The shelf 250 can be disposed against the filter 214 opposite the lid 204 in relation to the chamber 215. In at least one example, the shelf 250 can be coupled, for example welded, fused, and/or adhered, to the filter 230 so that the filter 214 is operable to be breached (e.g., punctured) by the brewing pin 126 without letting any beverage material 216 escape from the chamber 215.

The shelf 250 can include of a suitable material to prevent the brewing pin 126 from fully breaching the shelf 250, such as, but not limited to metal, a plastic, or a polymeric material derived from polylactic acid, Ingeo™, or poly-L-lactide . In some examples, the shelf 250 can be made of a material that is biodegradable and preferably, the material is also compostable and fully plant based.

In some examples, the shelf 250 can allow for precise location of the filter 214 to any desired depth within the beverage pod 200. For example, the shelf 250 can allow for more precise positioning so that of the filter 214 can be disposed to a position closer to the bottom of the beverage pod 200 which can increase the volume available for the loading of beverage material 216 into the beverage pod 200. In some examples, the shelf 250 can provide more efficient control of the dosing of the beverage material 216. For example, since the shelf 250 facilitates the positioning of the filter 214 lower into the beverage pod 200, for a given amount, there would be a reduced likelihood of spillage of beverage material 216 over the rim of the beverage pod 200 which minimizes waste of the beverage material 216. Additionally, in some examples, the diameter of the shelf 250 can dictate the depth at which the filter 214 can be seated in a typical frustoconically shaped beverage pod 200 and therefore, the shelf 250 can efficiently facilitate the positioning of the filter 214 into the beverage pod 200.

In some examples, the shelf 250 can increase the quality of the brewed beverage because the shelf 250 when subjected to the upward movement of the brewing pin 126 can function similar to a piston that exerts pressure and compresses the beverage material 216 in the chamber 215 to allow for better extraction during the brewing process.

With the shelf 250 and the additional volume of the chamber 215 due to the filter 214 shape, the receiving portion 260, as illustrated in FIG. 2, can have substantially a toroidal shape.

The beverage pod 200 can include a bottom layer 205. The bottom layer 205 is operable to be breached by the brewing pin 126. The bottom layer 205 is operable to seal away the first beverage material 216 and/or the beverage formed from the liquid and the beverage material 216 from the external elements until the beverage pod 200 is pierced by the brewing pin 126.

The lower, or exterior, bottom layer 205 is the bottom external portion of the beverage pod 200 opposite the lid 204. The bottom layer 205 can be made from the same material as the rest of the pod exterior 208, or it can be made of a thinner material, such as foil, PLA web, cellulose fiber paper, and/or any combination of materials.

FIGS. 3A-3B illustrate a beverage pod 20 where the chamber 315 can extend towards the bottom 305 of the beverage pod 20 in both the center and the sides of the beverage pod 20. Accordingly, even more volume can be captured for increasing and/or maximizing the amount of beverage material 216 to provide the optimum beverage. The shelf 350 can form a receiving portion 360 that has substantially a toroidal shape. In some examples, as shown in FIGS. 3A-3B, the shelf 350 can form a receiving portion 360 that has substantially a toroidal polyhedron shape.

In at least one example, the circular shelf 350 is located at the bottom 305 of the pod 20 on the interior of the beverage pod 20, providing a void as a receiving portion 360 where the brewing pin 126 may be received after breaching the bottom layer 305 without interacting with the beverage material 316, for example by not contacting or damaging any portion of the filter 314. The receiving portion 360 formed by the circular shelf 350 may be conical, cylindrical, or some other shape that provides support for the protruding chambers 321, 322 formed by the filter 314 and protection from the brewing pin 126 of the brewing beverage machine 10.

The receiving portion 360 can be formed based on the position, shape, and size of the brewing pin 126 in relation to the beverage pod 20. The receiving portion 360 can be wider at the bottom (e.g., proximate the bottom layer 305) than it is at the top (e.g., proximate the filter 314) so as to ensure the brewing pin 126 is guided into the proper position. In some examples, the shelf 350 can be a structural feature disposed in the outer shell 308 of the beverage pod 20. The shelf 350 can support the shape of the filter 314 and maintain the shape of the receiving portion 360.

The shelf 350 and the filter 314 can create new volumes available for additional beverage material 322 in the center of the pod 20 on the inside of the receiving portion 360 (e.g., central chamber 321) and along the outer edge of the beverage pod 20 between the receiving portion 360 and the outer shell 308 (e.g., outer chamber 320). This newly available volume in the beverage pod 20 can be filled in a number of ways. While the disclosure references an outer chamber 320, a central chamber 321, and a main chamber 319, these chambers 315 may all form one single chamber 315 without any separation between the chambers 315. In some examples, the chambers 315 can each be separated, for example, by a separation filter 318 to keep the corresponding beverage materials 316, 322 separate if desired. The main chamber 319 can be similar to a shape and size of a conventional chamber (for example as shown in FIG. 1B). The outer chamber 320 and/or the central chamber 321 provide the additional volume to critically maximize the amount of beverage material 316.

The outer chamber 320 and the central chamber 321 can be formed into a filter 314 in a number of different ways. The edge is, for example, can created through an ultrasonic welding process, but could also be done with methods such as, laid down, spun bound, extruded, or mechanically created with a male and female die. In some examples, the newly available volume provided by the outer chamber 320 and the central chamber 321 can be filled with a second filter pouch, creating a filter barrier 318. The addition of the outer chamber 320 and the central chamber 321 provide a significant amount of additional volume for beverage material 316. A conventional short filter 114 which does not extend into the lower portion of the beverage pod 20 may capture as much as 70% of the total beverage pod volume. However, the additional volume of the outer chamber 320 and the central chamber 321 extending into the lower area of the beverage pod 20 may allow as much as 89% of the total beverage pod volume to be used for beverage material 316. This significant increase in useable volume provides a beverage pod 20 capable of brewing a beverage at an increased strength compared to the conventional short filter design, or a beverage at the same strength with addition beverage volume. Additionally, in comparison to the example beverage pod 200 in FIG. 2 with only a central chamber 220, the outer chamber 320 can provide almost 4 to 5 times the volume than just the central chamber 321. Accordingly, by including both the outer chamber 320 as well as the central chamber 321, the usable volume in the beverage pod 20 is maximized.

As the filter 314 may deform upon introduction of hot liquid and pressure, the shelf 350 can provide support to the filter 314 to maintain the shape. Accordingly, the shape of the shelf 350 can form the shape of the receiving portion 350 and can correspond to the shape of the filter 314 that creates the additional volume from the outer chamber 320 and the central chamber 321. As the details of the shape of the shelf 350 is discussed herein, the filter 314 can correspondingly have the same angles and shapes.

FIGS. 4A-4H illustrate a support component 401 which can be inserted into an outer shell 408 of a beverage pod 400. The support component 401 can include a shelf 450, similar to the shelf 250, 350 in FIGS. 2-3B, but also includes side walls 451 (for example as shown in FIGS. 4B and 4C) that can abut and/or be coupled with the outer shell 408.

FIGS. 4A-4H illustrates a top view of the support component 401 with the shelf 450. The shelf 450, as illustrated in FIGS. 4A-4H, includes an outer surface 441 and an inner surface 442. The outer surface 441 can extend towards a center of the beverage pod 20 and/or the center of the shelf 450 from the side walls 451 of the support component 401 and/or the side walls of the outer shell 408. In at least one example, the outer surface 441 can extend towards the center while extending away from the bottom 453 of the shelf 450 and/or the bottom layer 405 of the beverage pod 20.

The inner surface 442 can extend towards the center of the beverage pod 20 and/or the center of the shelf 450, for example from the outer surface 441. The inner surface 442 can extend towards the center between the center and the outer surface 441. In other words, the outer surface 441 can be located between the inner surface 442 and the side walls 451. In at least one example, the inner surface 442 can extend towards the center while also extending towards the bottom 453 of the shelf 450 and/or the bottom layer 405 of the beverage pod 20.

While the figures illustrate that the outer surface 441 directly intersect with the inner surface 442, in some examples, one or more surfaces can be positioned between the outer surface 441 and the inner surface 442. For example, a planar surface parallel with the bottom layer 405 of the beverage pod 400 can connect the outer surface 441 and the inner surface 442.

As illustrated in FIG. 4B, the support component 401 can be disposed within the outer shell 408 of the beverage pod 400. The shelf 450 can be disposed proximate the bottom 405 of the outer shell 408 such that the shelf 450 forms the receiving portion 460 operable to receive the brewing pin 126. In at least one example, the shelf 450 can be disposed between the bottom layer 405 and the filter 414 such that the shelf 450 can support at least a portion of the filter 414 to prevent deformation and/or loss of shape of the filter 414 and the receiving portion 460. In some examples, as discussed above, the shelf 450 can be disposed within the chamber 415 such that the shelf 450 is disposed between the filter 414 and the lid 404, serving as a registration element.

As the shelf 450 has an outer surface 442 and an inner surface 441, the filter 414 can have a corresponding shape to the shelf 450. The filter 414 can be formed to abut against the outer surface 441 and the inner surface 442. For example, the filter 414 can include an outer surface 491 which corresponds with the shape and/or is supported by the outer surface 442 of the shelf 450. The filter 414 can also include an inner surface 492 which corresponds with the shape and/or is supported by the inner surface 441 of the shelf 450. In at least one example, the filter 414 can include side walls 480 which can correspond with, be in contact with, and/or be coupled with the side walls 451 of the supporting structure 401. In some examples, if the supporting structure 401 only includes the shelf 450 without the side walls 451, the filter 414 can be in contact with, be coupled with, and/or have a shape that corresponds with the side walls of the outer shell 408.

The outer surface 442 and the inner surface 441 are positioned at a supporting angle in relation to one another in order to form the receiving portion 460. Accordingly, the receiving portion 460 can receive the brewing pin 126 without the brewing pin 126 damaging the filter 414 and/or interacting with the brewing material 416 in the chamber 415. The brewing pin 126 can then retrieve the beverage from within the beverage pod 20 without getting clogged or allowing beverage material 416 to be present in the user's cup 7. Meanwhile, the volume of beverage material 416 in the beverage pod 20 is maximized and/or optimize the TDS and resulting beverage.

As shown in FIGS. 4C and 4D, the side walls 451 of the supporting structure 401 can include one or more protrusions 495 extending radially outward from the side walls 451. The one or more protrusions 495 can assist in coupling the supporting structure 401 with the outer shell 408. In at least one example, the supporting structure 401 can be coupled to the outer shell 408 by welding. However, in some examples, the outer shell 408 can separate from the side walls 451 of the supporting structure 401. Accordingly, the protrusions 495 can help hold and keep the fiber in the outer shell 408 in addition to welding or without the need of welding.

In at least one example, the shelf 450 can include a central surface 444 which can support the filter 414 between the inner surface 442. In at least one example, the central surface 444, as shown in FIGS. 4C and 4D, can include at least one rod to assist in supporting the shape of the filter 414 while providing passage of the beverage to the receiving portion 460.

The shelf 450, for example the outer surface 441, the inner surface 442, and/or the central surface 444, can form a plurality of holes 470 which permit passage of the beverage to the receiving portion 460. The size and/or shape of the holes 470 can vary so long as the shelf 450 is able to sufficiently support the shape of the filter 414 but still allowing sufficient flow of the beverage to pass through the filter 414 to the receiving portion 460. For example, as shown in FIG. 4F, the holes 470 formed in the outer surface 441 can have a width 470W between about 0.4 millimeters to about 0.8 millimeters. In some examples, the width 470W can be between about 0.5 millimeters and about 0.6 millimeters, alternatively about 0.57 millimeters.

In at least one example, as illustrated in FIGS. 4A-4H, the inner surface 442 can extend towards the center at a support angle 442A (shown in FIG. 4G) in relation to the outer surface 441. In at least one example, the support angle 442A can be between 30 degrees and 55 degrees. In some examples, the support angle 442A can be between 40 degrees and 50 degrees. In some examples, the support angle 442A can be between 46 degrees and 47 degrees, alternatively about 46.87 degrees. In some examples, such as in the example shown in FIG. 2, the support angle 442A can be between 90 degrees and 120 degrees. The support angle 442A forms the receiving portion 460 such that the receiving portion 460 can receive the brewing pin 126 without the brewing pin 126 damaging the filter 414, the shelf 450, and/or interacting with the beverage material 416 in the chamber 415. Correspondingly, the filter 414 can have an angle formed between the outer surface 491 and the inner surface 492 that corresponds with the support angle 442A.

In at least one example, the outer surface 441 can extend from the side walls 451 and/or the outer shell 408 at a side angle 441A. In some examples, the side angle 441A can be between 30 degrees and 40 degrees. In some examples, the side angle 441A can be between 33 degrees and 36 degrees, alternatively between 34 degrees and 35 degrees, alternatively about 34.58 degrees. Correspondingly, the filter 414 can have an angle formed between the outer surface 491 and the side walls 480 that corresponds with the side angle 441A.

In at least one example, the side walls 451 can have a thickness 451T between 0.4 millimeters and 0.7 millimeters, alternatively about 0.6 millimeters. The thickness 451T of the side walls 451 can be sufficient to help support the shape of the filter 414 and coupling to the outer shell 408 while not materially affecting the size of the chamber 415 and the volume of beverage material 416.

Referring to FIG. 4H, the outer surface 441 and a longitudinal axis X-X can form an outer surface angle 441X. In at least one example, the outer surface angle 441X can be between 27 degrees and 90 degrees, alternatively between 30 degrees and 34 degrees, alternatively between 32 degrees and 33 degrees, alternatively about 32.05 degrees. Correspondingly, the filter 414 can have an angle formed between the outer surface 491 and the longitudinal axis X-X that corresponds with the outer surface angle 441X.

In at least one example, the width 441W between the bottom of the outer surface 441 (e.g., the bottom 453 of the shelf 450) and the end of the inner surface 442 (e.g., where the inner surface 442 intersects with the central surface 444) can be between 4 millimeters and 9 millimeters, alternatively between 5 millimeters and 8 millimeters, alternatively between 6 millimeters and 7 millimeters, alternatively about 6.68 millimeters. The width 441W is sufficient to form the receiving portion 460 to receive the brewing pin 126 while providing adequate space in case the brewing pin 126 does not breach the bottom layer 405 of the beverage pod 400 in the exact same position every time.

In at least one example, the inner surface 442 and the longitudinal axis X-X can form an inner surface angle 442X. The inner surface angle 442X can be between 12 degrees and 17 degrees, alternatively between 13 and 16 degrees, alternatively between 14 degrees and 15 degrees, alternatively about 14.82 degrees. Correspondingly, the filter 414 can have an angle formed between the inner surface 492 and the longitudinal axis X-X that corresponds with the inner surface angle 442X.

In at least one example, the side wall 451 of the supporting structure 401 and the longitudinal axis X-X can form a side wall angle 451X. The side wall angle 451X can be between 3 degrees and 6 degrees, alternatively between 4 degrees and 5 degrees, alternatively about 4.82 degrees. Correspondingly, the filter 414 can have an angle formed between the side walls 480 and the longitudinal axis X-X that corresponds with the side wall angle 451X.

In at least one example, the central surface 444 can be sufficiently linear. In some examples, the central surface 444 can have a radius of curvature 444R to enhance the strength of the supporting structure 450 to support the filter 414. In some examples, the radius of curvature 444R can be between 10 millimeters and 30 millimeters, alternatively between 15 millimeters and 25 millimeters, alternatively between 19 millimeters and 22 millimeters, alternatively between 20 millimeters and 21 millimeters, alternatively about 20.21 millimeters. Correspondingly, the filter 414 can have a central portion that corresponds with the central surface 444 and has a radius of curvature that corresponds with the radius of curvature 444R.

In at least one example, the shelf height 450H between the bottom 453 of the shelf 450 (e.g., the bottom of the outer surface 441 and/or the intersection between the outer surface 441 and the outer walls 451) and the intersection of the inner surface 442 and the outer surface 441 can be sufficient to form a receiving portion 460 that can receive the brewing pin 126. In some examples, the shelf height 450H can be between 7 millimeters and 13 millimeters, alternatively between 9 millimeters and 12 millimeters, alternatively between 10 millimeters and 11 millimeters, alternatively about 10.99 millimeters.

In at least one example, a height 444H between the intersection of the inner surface 442 and the central surface 444 and the intersection of the outer surface 441 and the inner surface 442 can be sufficient to form a receiving portion 460 that can receive the brewing pin 126 while allowing space for beverage passing through the central surface 444 to flow to the receiving portion 460. In some examples, the height 444H can be between 6 millimeters and 12 millimeters, alternatively between 8 millimeters and 11 millimeters, alternatively between 9 millimeters and 10 millimeters, alternatively about 9.18 millimeters.

The specific shape and dimensions of the shelf 450 and/or the filter 414 form the receiving portion 460 which can properly receive the brewing pin 126 while optimizing the volume of beverage material 416 within the beverage pod 400. Accordingly, the resulting beverage from the beverage pod 400 is optimized to provide the best flavor and concentration.

The embodiments shown and described above are only examples. Even though numerous characteristics and advantages of the present technology have been set forth in the foregoing description, together with details of the structure and function of the present disclosure, the disclosure is illustrative only, and changes may be made in the detail, especially in matters of shape, size and arrangement of the parts within the principles of the present disclosure to the full extent indicated by the broad general meaning of the terms used in the attached claims. It will therefore be appreciated that the embodiments described above may be modified within the scope of the appended claims. 

What is claimed is:
 1. A beverage pod comprising: an outer shell having a bottom layer, a lid opposite the bottom layer, and side walls between the bottom layer and the lid, wherein the bottom layer is operable to be breached by a brewing pin from a beverage brewing machine; a filter forming a chamber operable to contain a beverage material, the beverage material operable to mix with a liquid to form a beverage; a shelf supporting a shape of at least a portion of the filter, the shelf forming a receiving portion operable to receive the brewing pin, the receiving portion having substantially a toroidal shape.
 2. The beverage pod of claim 1, wherein the receiving portion has substantially a toroidal polyhedron shape.
 3. The beverage pod of claim 1, wherein the shelf includes an outer surface extending towards a center of the beverage pod from the side walls and an inner surface extending towards the center between the center and the outer surface at a support angle in relation to the outer surface.
 4. The beverage pod of claim 3, wherein the support angle is between 30 degrees and 55 degrees.
 5. The beverage pod of claim 3, wherein the support angle is between 40 degrees and 50 degrees.
 6. The beverage pod of claim 3, wherein the support angle is between 46 degrees and 47 degrees.
 7. The beverage pod of claim 3, wherein the support angle is between 90 degrees and 120 degrees.
 8. The beverage pod of claim 3, wherein the outer surface and a longitudinal axis form an outer surface angle, wherein the outer surface angle is between 27 degrees and 90 degrees.
 9. The beverage pod of claim 8, wherein the outer surface angle is between 30 degrees and 34 degrees.
 10. The beverage pod of claim 3, wherein the inner surface and a longitudinal axis form an inner surface angle, wherein the inner surface angle is between 12 degrees and 17 degrees.
 11. The beverage pod of claim 3, wherein the filter is formed to abut against the outer surface and the inner surface.
 12. The beverage pod of claim 1, wherein the shelf forms a plurality of openings such that the beverage passes through the filter and through the plurality of openings into the receiving portion.
 13. A shelf operable to be disposed in a beverage pod to support a shape of a filter, the shelf comprising: an outer surface extending towards a center; and an inner surface extending towards the center between the center and the outer surface at a support angle in relation to the outer surface, wherein the outer surface and the inner surface form a receiving portion having substantially a toroidal shape.
 14. The shelf of claim 13, wherein the support angle is between 30 degrees and 55 degrees.
 15. The shelf of claim 13, wherein the support angle is between 40 degrees and 50 degrees.
 16. The shelf of claim 13, wherein the support angle is between 90 degrees and 120 degrees.
 17. The shelf of claim 13, wherein the outer surface and a longitudinal axis form an outer surface angle, wherein the outer surface angle is between 27 degrees and 90 degrees.
 18. The shelf of claim 17, wherein the outer surface angle is between 30 degrees and 34 degrees.
 19. The shelf of claim 13, wherein the inner surface and a longitudinal axis form an inner surface angle, wherein the inner surface angle is between 12 degrees and 17 degrees.
 20. The shelf of claim 13, wherein the shelf forms a plurality of openings such that a beverage passes through the plurality of openings into the receiving portion. 